Advances in Commercial Generators and Distribution Solutions

By CE Contributing Authors August 14, 2014 View Profile

Power Gen Evolutions

By Rafael Acosta

Not long ago, a “portable” generator was something that could be loaded into the back of a pickup truck, and it lacked the power to service a large commercial or industrial operation. Today, thanks to advancements in everything from computerization to the tensile strength of materials, manufacturers are making radical leaps in the amount of power they can build into a reasonably compact — even portable — package. In addition, specialized add-on equipment, from workhorse distribution panels to energy-saving bi-fuel systems, are increasing the efficiency and relevance of compact generators for commercial and industrial concerns. In this article, we’ll talk about some of these advances and how they can help you run your operation.

Compact Industrial Generators
Industrial diesel and natural gas generators are benefiting greatly from miniaturization and other technologies that let manufacturers put more power into an efficiently-sized package. It’s possible to find fully portable generators now with working power ratings of several megawatts (MW). Some of these are stationary, enclosed units that must be lifted by crane to be moved from one location to the next. However, using a truck-type chassis, it’s also possible to create towable units with working power ratings of more than 2 MW. That’s enough electricity to power 1,000 average-sized homes.

Telematics & Remote Operation
For companies using generators in remote locations, whether they are running sprinklers in the far-most field of a grower’s farm or acting as part of a wind-diesel hybrid power plant, perhaps no development is more exciting than the growth of telematics. These sophisticated apparatuses can be integrated into compact, enclosed generators, enabling the generator operator to communicate directly with the engine and other components to receive vital information. Operators and/or their service companies can receive maintenance reminders to schedule service, monitor and act upon warnings, overloads and other alerts and even resolve engine problems — all from a remote location. This feature reduces costly unexpected failures, increases longevity and run time and maximizes ROI.

Bi-Fuel Generators Save Fuel Costs
Another area where manufacturers are making strides with portable generators is in fuel source options. New bi-fuel, add-on systems are enabling diesel generators to burn up to 70 percent natural gas, saving operators up to 50 percent on fuel costs compared to burning diesel fuel alone. For companies that are space constrained, these systems can be installed on an enclosed or even portable generator then connected to an available gas supply for ultimate operating flexibility. For more space-saving convenience, purchasers can have a diesel fuel tank installed on the bottom of many enclosed generators, creating a single and compact operating package.

Power Distribution Panels
Power distribution gear, which gives operators access to a generator’s power supply for everything from charging cell phones to powering outdoor lighting, are becoming increasingly sophisticated, useful and, in many cases, portable. Not only are advanced power panels being built into compact, enclosed generators, but companies can now purchase well-equipped, highly portable, Nema 3R-rated power distribution boxes that offer transformer, step-up/step-down and other capabilities in a single piece of equipment. Whether built into a portable generator or connected to them, the best of these power distribution units incorporate a wealth of features. These include dual-voltage-input CSA and UL-listed transformers, UL 1640-listed power distribution panels, Camloks with color-coded covers and more.

Facilitating Fast Recovery
One really exciting development, in our opinion, is the appearance of “quick connect” power distribution boxes designed specifically to enable a portable generator to replace a permanent, standby or prime generator in the event of an outage (planned or unplanned). These devices make the connection between a generator and the main power feed for a building without the need to have an electrician set up long cabling runs and make time-consuming connections.

For example, once a company installs one of these boxes, they can tow in a generator and connect it quickly every time a standby or backup generator needs to come down for maintenance. Buildings with these boxes installed can regain power after an outage quickly, as well, without the need for an electrician. In both cases, the boxes tap into the same power feed used for the existing prime or standby power source.
When needed, a portable generator can connect directly to the box, because all wiring normally required to bring an external power supply into an interior location has been hooked up in advance. There is currently no industry standard for these units, which go by many names including “generator roll-up boxes” and “generator connection cabinets” (the name Hipower Systems uses).

The Crystal Ball
Although all these developments are significant, they merely hint at the future of power equipment advances. We predict that the market for portable generators will continue to accelerate, especially with the increasing demand for backup generators to protect against weather outages and grid overloads. That growth should drive manufacturers’ efforts to give companies the power they need in an ever-more functional yet compact package.